Mylar blended plate and package

ABSTRACT

A package that comprises a bottom, a plurality of sidewalls extending away from the bottom defining an open top, each sidewall coupled to the bottom with a bottom-to-sidewall transition. The package may include a plurality of curved corner sidewalls disposed between the sidewalls and coupled to the bottom with a bottom-to-corner transition. The bottom-to-sidewall transition may comprise three sections, wherein a second section is substantially planar or slightly arced and the first and third sections being curved as necessary. The package may also include the bottom-to-corner transition comprising at least three sections, the second section being substantially planar wherein the first and third sections are curved as necessary. The second sections of both transitions may be angularly orientated to the bottom and sidewalls. The package may further include a plurality of transition elements between to couple the bottom-to-corner and bottom-to-side transitions.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 61/792,090, filed Mar. 15, 2013, the entire disclosure of which is hereby incorporated by reference.

FIELD OF THE INVENTION

This present invention relates to a shape of a deep drawn thermoplastic package and a plate for deep drawing the same which improves on the prior art by equalizing the film distribution during the formation process to improve the draw ratio.

BACKGROUND OF THE INVENTION

Deep drawn packaging has become very prevalent throughout the food packaging industries. As shown in FIG. 8, existing deep-drawn thermoplastic containers 400 have a substantially horizontal base 402, four substantially vertical sidewalls 404 a, 404 b, 404 c and 404 d; four curved corner transitions 406 a, 406 b, 406 c, and 406 d; and three different curved transition sections 408 a, 408 b and 408 c which comprise the transition between the base 402, the sides 404 a-d and the corners 406 a-d. The four sidewalls define an open top 410 and a flange 412 that extends around the perimeter of open top 410. The curved transitions 408 a-c are incorporated into such packages due to limitations of the films materials to be formed such that walls intersect at corners. The curved transitions 408 a-c also makes the package easier to remove from the mold. However, to maximize the volume of the packaging, the radius of curvature remains relatively small to provide a minimum reduction in the area of the bottom of the package resulting in a desired stress distribution in the packaging materials.

The existing configuration performs well for shallow packaging. However, as the sidewalls are drawn deeper, the currently existing bottom-to-side curved transitions result in a non-uniform distribution of material throughout the package as the sidewalls bear a disproportionate thinning when compared to the bottom or the transition sections. Thus, there is a need in the art for a revised package shape and mold or plate particularly for deep-drawing packages which improve the material distribution throughout the package and thereby increases the overall strength of the package and lessens the risk of tears or ruptures of the packaging at the thinner portions of the packaging.

SUMMARY OF THE INVENTION

The present application is directed toward a package, primarily for foodstuffs, that comprises a bottom and a plurality of sidewalls extending away from the bottom. The sidewalls may be connected using a plurality of curved corner sidewalls. The sidewalls and corner sidewalls may define an open top. Each sidewall may be coupled to the bottom with a bottom-to-sidewall transition. The plurality of curved corner sidewalls may be disposed between the sidewalls. One embodiment of the present package may include four sidewalls extending way from and substantially perpendicular to the bottom and four curved corner sidewalls disposed between the four sidewalls. The package may be thermoformed and/or deep-drawn and incorporated into a food packaging machine. The package may be of unitary construction.

The transitions between the bottom and the sidewalls may be a bottom-to-sidewall transition that includes at least three sections. The second section may be substantially planar, wherein the first section is a curved transition between the bottom and the second section and a third section may be a curved transition between the second section and one of the sidewalls. The second section of the bottom-to-sidewall transition lies at an angle with respect to the bottom. The angle may be in a range between thirty and sixty degrees and, may more specifically be around forty-five degrees.

The package may also include a bottom-to-corner transition that includes at least three sections. Similarly, the second section may be substantially planar, and the first section may be curved and provides a transition between bottom and second section. The third section may include a surface having at least two curves and provides a transition between second section and one of the curved corner sidewalls.

Embodiments of the present package may further include transition elements to transition between bottom-to-sidewall transition and the bottom-to-corner transition so that the package may be leak-proof or air-proof and of a unitary construction. A first transition element provides a transition between the first section of the bottom-to-sidewall transition and the first section of the bottom-to-corner transition. A second transition element to transition between the second section of the bottom-to-sidewall transition and the second section of the bottom-to-corner transition. The package may also include a segmented transition between the third section of the bottom-to-sidewall transition and the third section of the bottom-to-corner transition. A portion of the segmented transition may be coupled to the second section of the bottom-to-corner transition.

In an alternative embodiment, the package of the present invention may alternatively include the bottom-to-sidewall transition having three sections, wherein the second section is an arc of a first radius. The first section may be a curved transition between the bottom and the second section, and the first section may have a second radius. The third section may be a curved transition between the second section and one of the sidewalls wherein the third section may have a third radius. In one embodiment, the first radius is greater than both the second radius and the third radius.

The present invention may also be directed toward a plate for forming the above package and/or a packaging machine that includes a plate for forming the above package.

Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and the accompanying drawing figures.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The accompanying drawings form a part of the specification and are to be read in conjunction therewith, in which like reference numerals are employed to indicate like or similar parts in the various views.

FIG. 1 is a perspective view of a package formed in accordance with the teachings of the present disclosure;

FIG. 2 is a top view of the package of FIG. 1;

FIG. 3 is a front view of the package of FIG. 1;

FIG. 4 is an end view of package of FIG. 1;

FIG. 5 is a section view of the package of FIG. 2 cut along the line 5-5;

FIG. 6A is a section view of the package of FIG. 2 cut along the line 6-6;

FIG. 6B is a section view of an alternative embodiment of the section of FIG. 6A in accordance with the teachings of the present disclosure;

FIG. 7 is a close up perspective view of a corner of the package of FIG. 1; and

FIG. 8 is a perspective view of a prior art package which is improved by the present package.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description of the present invention references the accompanying drawing figures that illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the present invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the spirit and scope of the present invention. The present invention is defined by the appended claims and, therefore, the description is not to be taken in a limiting sense and shall not limit the scope of equivalents to which such claims are entitled.

As shown in FIG. 1, the present packaging 10 includes a bottom 12, a first sidewall 14, a second sidewall 16, a third sidewall 18, a fourth sidewall 20, an open top 22 defined by the sidewalls 14, 16, 18, and 20, and a flange 24 disposed around the perimeter of the open top 22.

First sidewall 14 includes a top 26, a bottom 28, a first end 30 and a second end 32. Second sidewall 16 includes a top 34, a bottom 36, a first end 38 and a second end 40. Third sidewall 18 includes a top 42, a bottom 44, a first end 46 and a second end 48. Fourth sidewall 20 includes a top 50, a bottom 52, a first end 54 and a second end 56. Package 10 may be any material used in the art for deep-drawing including plastic materials commonly used in the art including, known polymers, polypropylene, polyvinyl, polyester, PET, plastics, and Mylar.

As further shown in FIG. 1, a first corner sidewall 58 joins first end 30 of first sidewall 14 and second end 40 of second sidewall 16. The package 10 further includes a second corner sidewall 60 joining first end 38 of second sidewall 16 and second end 48 of third sidewall 18; a third corner sidewall 62 joining first end 46 of third sidewall 18 and second end 56 of fourth sidewall 20; and a fourth corner sidewall 64 joining first end 54 of fourth sidewall 20 and second end 32 of first sidewall 14.

Package 10 of the present invention also includes a multiple step transition from the base to the sidewalls that lowers the draw-ratio of the packages thereby resulting in a more uniform distribution of the packaging material. In essence, one embodiment of package 10 combines a chamfer with two fillet radius transitions to transition from bottom 12 of the package to the sidewalls 14, 16, 18, and 20. Similar transition structure is provided in the corners and by reducing the surface area, it subsequently reduces the amount the film must stretch in the corners and, thereby results in a thicker film. This configuration, however, reduces the total surface area of package 10 when compared to the simple fillet radius transition of the package 400 illustrated in FIG. 8.

As shown in FIG. 2, a bottom-to-sidewall transition 66 a, 66 b, 66 c, and 66 d comprises at least a first section 68 a-d, a second section 70 a-d, and a third section 72 a-d. Second sections 70 a-d are one of a chord member having a linear profile or an arc length having a very large diameter and may result in a member that may appear straight or substantially planar. First sections 68 a-d are curved transition sections that provide the transition from bottom 12 to second sections 70 a-d. Third sections 72 a-d may also be curved transition sections that transition from second section 70 a-d to an adjacent sidewall 14, 16, 18, or 20. As shown in FIG. 2, each first section 68 a-d respectively includes a top side 74 a-d, a bottom side 76 a-d, a first side 78 a-d and a second side 80 a-d. Each second section 70 a-d respectively includes a top side 82 a-d, a bottom side 84 a-d, a first side 86 a-d and a second side 88 a-d. In general, top side 74 of first section 68 will intersect with bottom side 84 of second section 70 and bottom side 76 of first section 68 intersects with bottom 12 at each transition. Second section 70 may be substantially planar or may include a slight arc due to a large radius.

Further, each third section 72 a-d respectively includes a top side 90 a-d, a bottom side 92 a-d, a first side 94 a-d and a second side 96 a-d. As shown in FIG. 2, in general top side 82 of second section 70 intersects with bottom side 92 of third section 72 and, as shown in FIG. 3, top side of 90 a of third section 72 a intersects with the adjacent sidewall 14 for each transition. As shown in FIG. 4, top side 90 b of third section 72 b intersects with sidewall 16. Similarly, top sides 90 c-d of third sections 72 c-d will intersect with sidewalls 18, and 20 respectively.

Now turning back to FIG. 2, the bottom-to-corner transitions 98 a, 98 b, 98 c, and 98 d respectfully comprise at least a first section 100 a-d, a second section 102 a-d, and a third section 104 a-d. Each first section 100 a-d respectively includes a top side 106 a-d, a bottom side 108 a-d, a first side 110 a-d and a second side 112 a-d. Each second section 102 a-d respectively includes a first inclined top side 114 a-d, a second inclined top side 116 a-d, a bottom side 118 a-d, a first side 120 a-d and a second side 122 a-d. Generally, top side 106 of first section 100 intersects bottom side 118 of second section 102 at each respective transition as shown. Second section 102 may be substantially planar or may include a slight arc due to a large radius.

Further, each third section 104 a-d respectively includes a curved top side 124 a-d, a curved bottom side 126 a-d, a first side 128 a-d, and a second side 130 a-d. As shown in FIG. 2, the curved intersection of first and second inclined top sides 114 and 116 of second section 102 intersects with the curved bottom side 126 of third section 104 and, as shown in FIG. 3, top sides 124 a and 124 d of third section 104 a and 104 d intersect with the adjacent corner sidewalls 58 and 64 as shown. Similarly (although not shown in FIG. 3), top sides 124 b and 124 c of third sections 104 b and 104 c will intersect with corner sidewalls 60 and 62 respectively.

FIG. 7 demonstrates that there are a number of transition elements which are required to transition from bottom to side transitions 66 b and 66 c to bottom-to-corner transition 98 b. The other corners of package 10 may be identically configured and are preferably configured as such. As shown in FIG. 7, a first transition element 132 a and 132 b transitions between first portions 68 b and 68 c of transitions 66 b and 66 c with first section 100 b of corner transition 98 b. First transition elements 132 a and 132 b respectively include a first side 136 a and 136 b and a second side 138 a and 138 b that respectively share a common intersection point 134 a and 134 b. First transition elements 132 a and 132 b have a respective top side 140 a and 140 b. Transition elements 132 will generally have a curved profile that varies and may transition gradually from side 136 a proximate side 80 b of first section 68 b to side 138 a proximate side 110 b of first corner section 100 b, and also transitions gradually from side 136 b proximate side 78 c of first section 68 c to side 138 b proximate side 112 b of first corner section 100 b.

Second transition elements 142 a and 142 b respectively include a bottom side 144 a and 144 b, a first side 146 a and 146 b, and a second side 148 a and 148 b, and a top side 150 a and 150 b. Transition element 142 will generally have a linearly appearing profile, but the element itself will curve from second section 70 b to side 122 b of second corner section 102 b and from second section 70 c to side 120 b of second corner section 102 b. Bottom side 144 a and 144 b intersect respectively with top side 140 a and 140 b of first section 132 a and 132 b as shown in FIG. 7.

Package 10 also includes two transition elements to transition from third sections 72 b and 72 c to third corner section 104 b as shown in FIG. 7. As such transition elements 152 a and 154 a, and 152 b and 154 b create a segmented transition respectively between sections 72 b, 72 c and third corner section 104 b. As shown, sections 152 a and 152 b include respectively a bottom side 156 a and 156 b, a first side 158 a and 158 b, a second side 160 a and 160 b, and a top side 162 a and 162 b. Generally for transition element 152, bottom side 156 intersects with top side 150 of transition element 142. First side 158 a intersects with side 96 b of third transition section 72 b, and first side 158 b intersects with side 94 c of third transition section 72 c. Top side 162 a intersects with bottom 36 of sidewall 16 and top side 162 b intersects with bottom 44 of sidewall 18.

Transition element 154 a and 154 b include a bottom side 164 a and 164 b, a first side 166 a and 166 b, a second side 168 a and b, and a top side 170 a and 170 b. Bottom side 164 a of transition element 154 a intersects second top inclined side 116 b of second corner section 102 b. Bottom side 164 b of transition element 154 b intersects first inclined side 114 b of second corner section 102 b. First side 166 a and 166 b respectively intersect with second sides 160 a and 160 b of transition elements 142 a and 142 b. Second side 168 a of transition element 154 a intersects with side 130 b of third corner section 104 b. Second side 168 b of transition element 154 b intersects with side 128 b of third corner section 104 b. Top side 170 a of transition element 154 a intersects with a portion of bottom 36 of sidewall 16 and a portion bottom 124 b of corner sidewall 60. Similarly, top side 170 b of transition element 154 b intersects with a portion of bottom 44 of sidewall 18 and a portion of bottom 124 b of corner sidewall 60. The profile of transition elements 154 a and 154 b have a curved profile and transition elements 152 a and 152 b have a wedge-like shape to accommodate the differences in the surface planes between the sidewall transitions 66 and the corner transitions 98.

Now turning to FIG. 5, corner transition 98 b includes second corner section 102 b being orientated at an angle α with respect to bottom 12. Angle α may be in a range between thirty (30) and sixty (60) degrees, but is preferably around forty-five (45) degrees. First corner section 100 b is curved to transition between bottom 12 and second corner section 102 b. Third corner section 104 b also curves to transition between corner sidewall 60 and second corner section 102 b. In one embodiment, second corner section 102 b is substantially linear and constitutes a chord member that is tangential to both first corner section 100 b and third corner section 104 b. The profile of bottom-to-corner transition 98 b compared with a typical single-element radius transition 408 c (shown in broken lines) having a radius R is shown. In another embodiment, second corner section may be non-tangential similar to the embodiment described below and shown in FIG. 6B. The transition 104 b from corner section 102 b to corner 60 may further include a shelf 200 which may provide some lateral stability to the package 10 or may serve other utilitarian or aesthetic purpose.

Now turning to FIG. 6A, bottom-to-side transition 66 c includes second section 70 c being orientated at an angle β with respect to bottom 12. Angle β may be in a range between thirty (30) and sixty (60) degrees, but is preferably around forty-five (45) degrees. First section 68 c is curved to transition between bottom 12 and second section 70 c. Third corner section 72 c also curves to transition between sidewall 18 and second section 70 c. In one embodiment, second section 70 c is substantially linear and constitutes a chord member that is tangential to one or both of first section 68 c and third section 72 c. The profile of bottom-to-side transition 66 c compared with a typical single-element radius transition 408 a (shown in broken lines) having a radius R is shown. The transition 72 c from corner section 70 c to side 18 may further include shelf 200 which may provide some lateral stability to the package 10 or may serve other utilitarian or aesthetic purpose.

FIG. 6B illustrates an alternative embodiment packaging 10′, which includes an alternative transition configuration than that shown in FIG. 6A and described above. FIG. 6B illustrates a non-tangential configuration of a bottom-to-side transition. In this embodiment, second section 70 is an arc length of a circle having a very large radius, and first section 68 and third section 72 may be curved at a lesser radius. As such, second section 70 will have a more abrupt transition with first section 68 and third section 72 in which a slight corner is formed, rather than a smooth curve associated with the tangential configuration shown in FIG. 6A. Similarly, the proposed three-stage non-tangential bottom-to-side transition is shown in comparison to a typical prior art single element curved transition 408 a formed at a radius R.

Now that the shape of the package formed by a packaging mold or plate has been described, a person in the art will appreciate forming a mold or a plate which results in a package of the above configuration. The angled and/or substantially planar second sections 70 and 102 of the package of the present disclosure provide an advantage when deep drawing the packaging to distribute material more uniformly throughout the package and, thus, avoiding weak or thin portions of the sidewall.

As is evident from the foregoing description, certain aspects of the present invention are not limited to the particular details of the examples illustrated herein. It is therefore contemplated that other modifications and applications using other similar or related features or techniques will occur to those skilled in the art. It is accordingly intended that all such modifications, variations, and other uses and applications which do not depart from the spirit and scope of the present invention are deemed to be covered by the present invention.

Other aspects, objects, and advantages of the present invention can be obtained from a study of the drawings, the disclosures, and the appended claims. 

We claim:
 1. A package that comprises: a bottom; a plurality of sidewalls extending away from said bottom defining an open top, each sidewall coupled to said bottom with a bottom-to-sidewall transition; a plurality of curved corner sidewalls disposed between said plurality of sidewalls; wherein a bottom-to-sidewall transition comprises at least three sections, wherein a second section is substantially planar and a first section is a curved transition between the bottom and the second section and a third section that is a curved transition between the second section and one of the plurality of sidewalls.
 2. The package of claim 1 comprising four sidewalls extending substantially perpendicular to said bottom, and four curved corner sidewalls disposed between said four sidewalls.
 3. The package of claim 1 wherein said second section of said bottom-to-sidewall transition lies at an angle with respect to said bottom.
 4. The package of claim 3 wherein said angle is in a range between thirty and sixty degrees.
 5. The package of claim 4 wherein said angle is around forty-five degrees.
 6. The package of claim 1 further comprising a bottom-to-corner transition comprising at least three sections, said second section being substantially planar wherein said first section is curved and transitions between bottom and second section, and third section has at least two curves and transitions between second section and curved sidewall.
 7. The package of claim 6 further comprising a first transition element to transition between said first section of said bottom-to-sidewall transition and said first section of said bottom-to-corner transition; a second transition element to transition between said second section of said bottom-to-sidewall transition and said second section of said bottom-to-corner transition; and an segmented transition between said third section of said bottom-to-sidewall transition and said third section of said bottom-to-corner transition.
 8. The package of claim 7 wherein a portion of said segmented transition is coupled to said second section of said bottom-to-corner transition.
 9. A plate for forming a package, the package comprising: a bottom; a plurality of sidewalls extending away from said bottom defining an open top, each sidewall coupled to said bottom with a bottom-to-sidewall transition; a plurality of curved corner sidewalls disposed between said plurality of sidewalls; wherein a bottom-to-sidewall transition comprises at least three sections, wherein a second section is substantially planar and a first section is a curved transition between the bottom and the second section and a third section that is a curved transition between the second section and one of the plurality of sidewalls.
 10. A packaging machine including the plate of claim
 9. 11. A package wherein the package comprises: a bottom; a plurality of sidewalls defining an open top, each sidewall coupled to said bottom with a bottom-to-sidewall transition; a plurality of curved corner sidewalls between said plurality of sidewalls; wherein the bottom-to-sidewall transition comprises three sections, wherein a second section is an arc of a first radius, wherein a first section is a curved transition between the bottom and the second section, the first section having a second radius, wherein a third section is a curved transition between the second section and one of the plurality of sidewalls, the first section having a third radius, and wherein said first radius is greater than both said second radius and said third radius. 